REL iREL Systems User manual

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REL,!Inc.!
57640!North!Eleventh!Street!
Calumet,!MI!!49913!
Phone:!(906)!337-3018!
Fax:!(906)!337-2930!
www.relinc.com! !

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All!rights!reserved.!!Printed!in!the!United!States.!!This!document!and!parts!thereof!
may!not!be!reproduced!or!copied!without!the!written!permission!of!REL,!Inc.!!
Contents!of!this!manual!must!not!be!distributed!to!a!third!party!nor!be!used!for!any!
unauthorized!purpose.!
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Correct!usage!of!this!machine!is!important!to!assure!the!expected!machine!
functionality!as!well!as!operator!safety.!!Read!this!manual!thoroughly.!
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The!information!in!this!document!is!subject!to!change!without!notice!and!should!not!
be!construed!as!a!commitment!by!REL,!Inc.!!REL,!Inc.!assumes!no!responsibility!for!
any!errors!that!may!appear!in!this!manual.!
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In!no!event!shall!REL,!Inc.!be!liable!for!incidental!or!consequential!damages!arising!
from!use!of!this!manual!or!of!the!software!and!hardware!described!in!this!manual.!
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For!questions,!comments,!or!concerns!please!contact!REL,!Inc.!during!normal!
business!hours:!!Monday!through!Friday,!8:00!am!to!5:00!pm!EST.!
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C@"R#$%(F(S(TA$%A&$Q ........................................................................................ 4
C@"R#$%(P(S(TR$%"#&1* ....................................................................................... 8
Getting!Started!..........................................................................................................................................................!8
Overview!......................................................................................................................................................................!8
Login!Page!................................................................................................................................................................!10
Zone!Screens!...........................................................................................................................................................!11
Alarm!Summary!.....................................................................................................................................................!14
Motor!MOA!Screens!.............................................................................................................................................!15
C@"R#$%(G(S(!"&*#$*"*/$ ................................................................................ 16
C@"R#$%(=(S(B".$#U............................................................................................. 17
Hazardous!Materials............................................................................................................................................!17
General!Safety!.........................................................................................................................................................!17
C@"R#$%(:(S(H%$A$*#&A$(!"&*#$*"*/$ ............................................................ 18
Introduction.............................................................................................................................................................!18
Routine!Maintenance!..........................................................................................................................................!18
C@"R#$%(<(S(0''D5#%"#$+(H"%#5(V%$"W+1Q*..................................................... 19
Corner!Turn!Tipple!Conveyor!.........................................................................................................................!19
Ramp!Conveyor!......................................................................................................................................................!21
Paint!Conveyor!.......................................................................................................................................................!22
Straight!Conveyor!.................................................................................................................................................!25
High!Speed!Tipple!.................................................................................................................................................!26
Board!Flipper!#1!...................................................................................................................................................!32
High!Speed!Corner!Transfer!............................................................................................................................!35
High!Speed!Tenoner!Transfer!.........................................................................................................................!38
Board!Accumulator!Conveyor.........................................................................................................................!38
Tipple!Conveyor!....................................................................................................................................................!42
Flipper!Accumulator!............................................................................................................................................!44
Turntable!Detail:!A!Design!&!Engineering!Example!............................................................................!45
3"%%"*#U ........................................................................................................... 46
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REL,!Inc.!builds!conveyor!systems!for!manufacturing!processes.!!This!example!project!
consists!of!a!new!corner!turn!tipple,!ramp!conveyor,!paint!conveyor,!powered!corner!turn!
and!straight!conveyors,!high!speed!tipple,!two!flipper!conveyors,!two!high!speed!corner!
transfer!conveyors,!a!board!accumulator,!and!tipple!conveyor.!!Included!in!this!project!is!a!
new!board!dryer!that!was!supplied!and!installed!by!others.!!The!conveying!system!is!
designed!to!process!boards!from!30”!x!60”!to!52”!x!120”.!!Following!is!a!brief!description!of!
each!piece!of!equipment!supplied!and!built!by!REL.!
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The!REL!Corner!Turn!Tipple!Conveyor!is!manufactured!to!smoothly!transition!the!board!to!
either!the!new!paint!line!or!to!by-pass!the!paint!line!and!continue!to!the!existing!main!line.!!
The!board!rides!on!lineshaft!driven!rollers!on!this!conveyor.!
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Figure 1: Example Overall Line Layout

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The!REL!Ramp! Conveyor! is!manufactured!to!smoothly!transition!the!board!from! the! 70”!
elevation! of! the! Quarter! Turn!Power! Curve! to! the! 42”!height!of!the!Paint!Conveyor.!! The!
board!rides!on!lineshaft!driven!rollers!on!this!conveyor.!
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The!REL! Paint! Conveyor! has!driven!infeed!and!outfeed! belt!beds!with!a!gap! provided!to!
accept!the!curtain!coater!provided!by!others.!!The!infeed!and!outfeed!conveyors!are!linked!
with!a!timing!belt!to!ensure!constant!speed!through!the!paint!conveyor.!!The!paint!is!applied!
with!the!board!completely!flat.!!The!corner!turn!conveyor!following!the!paint!conveyor!is!
positioned!such!that!the!board!will!not!start!turning!until!the!tail!end!has!exited!the!paint!
stream.!
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The!REL!Power!Curve!Conveyor!is!manufactured!to!smoothly!transition!the!board!around!
90!degree!corners!in!the!conveying!process.!!The!board!rides!on!lineshaft!driven!rollers!on!
these!conveyors.!
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The!REL!Straight!Conveyors!are!manufactured!to!move!the!board!in!the!conveying!process.!!
Edge!guides!are!provided!as!needed!to!control!product!flow.!!The!board!rides!on!lineshaft!
driven!rollers!on!these!conveyors.!
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The!REL!High!Speed!Tipple!Conveyor!consists!of!a!tipple!frame!that!incorporates!two!sets!of!
driven!belt!beds.!!It!is!designed!to!separate!the!incoming!product!stream!onto!two!stacked!
outfeed!conveyors!leading!to!the!board!flippers.!!Each!board!will!alternately!be!directed!to!
the!upper!level!and!Flipper!#2!or!the!lower!level!and!Flipper!#1.!!The!tipple!frame!pivots!
around! a!point! at!the! outfeed!end,!with!the!infeed!end!moving!up!and!down.!!As!a!board!
enters!the!tipple!in!the!down!position!(top!belt!bed),!the!tipple!starts!indexing!up!before!the!
board! is! completely! through.! ! The! next! board! enters! with! the! tipple! frame! in! the! raised!
position!(lower!belt!bed)!and!passes!completely!onto!the!tipple!conveyor!before!the!tipple!
indexes!back!to!the!down!position.!!The!tipple!frame!is!actuated!by!way!of!a!rotary!servo!
motor,!raising!or!lowering!the!frame!depending!on!the!sequence.!
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The!REL!Corner!Transfer/Overpass!Conveyor!is!built!to!either!feed!the!first!board!flipper!or!
by-pass! the! first! flipper! and! feed! the! second! board!flipper.! ! The! overpass! portion! of! this!
conveyor!consists!of!a!stationary!lineshaft!driven!roller!bed!that!moves!the!board!over!the!
top!of!the!corner!transfer!portion!of!this!conveyor!to!feed!the!second!board!flipper.! !The!
corner!transfer!portion!of!this!conveyor!consists!of!a!stationary!lineshaft!driven!roller!bed,!
and!pop-up!belt!transfer!with!an!integral!vacuum!system.!!The!function!of!the!corner!transfer!
portion!is!to!take!board!moving!down!the!line!and!change!its!direction,!exiting!at!a!right!angle!
to!the!infeed!flow!and!depositing!the!board!on!the!first!board!flipper.!!As!the!board!enters!
the!infeed!end!on!the!roller!bed,!sensors!indicate!position!up!against!the!stop!fence.!!The!belt!
bed! then! raises! by! way! of! a! rotary! servo! motor,! lifting! the! board!off! the! rollers! and!
transferring!it!off!the!conveyor.!!The!vacuum!assist!on!the!belt!bed!helps!in!maintaining!good!
contact!with!the!conveyor!belts!to!prevent!slipping!as!the!board!accelerates.!
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The!REL!Board!Flipper!Conveyors!are!built!to!flip!the!board!from!a!face!up!orientation!to!a!
face!down!orientation.!!Flipper!#1!consists!of!an!infeed!driven!belt!bed!that!transfers!the!
board!to!the!flipper!arms!that!perform!the!flipping!process,!and!an!out-feed!driven!belt!bed!
that!transfers!the!board!to!the!corner!transfer!conveyor.!!As!the!board!enters!the!infeed!end!
on!the!belt!bed,!sensors!detect!the!position!of!the!board!and!stop!the!infeed!belts!when!the!
leading!edge!of!the!board!reaches!the!pivot!point!of!the!flipper!arm!mechanism.!!The!lifting!
arm!side!of!the! flipper! tilts! the!board!to! approximately!90!degrees!allowing!the!board!to!
transfer!to!the!lowering!arm!side!of!the!flipper.!!The!lowering!arm!then!pivots!down!to!the!
horizontal!position!and!leaves!the!board!on!the!outfeed!belt!bed!which!moves!the!panel!on!
to!the!corner!transfer!conveyor.!!Flipper!#2!is!similar!to!flipper!#1!with!the!exception!that!it!
does!not!incorporate!an!infeed!belt!bed.!!The!lifting!flipper!arms!nest!with!the!rollers!on!the!
overpass!conveyor.!
Although! the! primary! purpose! of! the! this! line! is! to! paint! the! back! side! of! the! board,! a!
secondary!function!is!to!apply!a!third!coat!of!paint!to!the!front!side!of!the!board.!!In!this!mode!
all!board!will!travel!through!Flipper!#1,!but!will!not!be!flipped.!!The!board!will!simply!pass!
through!on!the!belt!conveyors.!
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The!REL!Corner!Transfer!Conveyor!consists!of!a!stationary!line!shaft!driven!roller!bed,!and!
pop-up!belt!transfer!with!an!integral!vacuum!system.!!The!function!of!the!corner!transfer!
conveyor!is!to!take!board!moving!down!the!line!and!change!its!direction,!exiting!at!a!right!
angle!to!the!infeed!flow.!!As!the!board!enters!the!infeed!end!on!the!roller!bed,!sensors!indicate!
position!up!against!the!stop!fence.!!The!belt!bed!then!raises!by!way!of!a!rotary!servo!motor,!
lifting!the!board!off!the!rollers!and!transferring!it!off!the!conveyor.!!The!vacuum!assist!on!the!
belt!bed!helps!in!maintaining!good!contact!with!the!conveyor!belts!to!prevent!slipping!as!the!
board!accelerates.!
The!two!high!speed!transfer!conveyors!on!the!outfeed!side!of!the!flippers!work!as!the!traffic!
control!conveyors!for!metering!the!two!product!streams!back!into!one!flow!going!into!the!
board!accumulator.!
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The!REL!Board!Accumulator!is!built!to!remove!board!from!the!line!flow,!store!the!board!in!
an! indexed! vertical! stack,! and! finally! placing! the! board!back! on! the! conveyor! line.!!This!
accumulator! has! the! capacity! to! empty! the! entire! dryer! to! eliminate! the! risk! of! fire.!The!
conveyor!consists!of!lineshaft!driven!rollers!to!move!the!board!through!the!conveyor!unit,!
and!sprocket!driven!chain!elevator!arms!on!both!sides!of!the!conveyor.!!The!elevator!arms!
lift!the! board!from! both! sides,! providing! adequate! support! for! the! entire! board.! ! The!
accumulator!has!the!capacity!to!store!35!boards.!
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The! REL! Tipple! Conveyor!is! built! to! move! the! board! running! on! this! line,! back! onto! the!
existing! conveyor! line.! ! The! conveyor! consists! of! a! powered! belt! conveyor! mounted! on!a!
tipple! frame! that! pivots! at! the! infeed! end,! lowering! the! outfeed! end! to! the! height! of! the!
existing!conveyor!line!elevation.!!The!tipple!frame!nests!with!the!existing!power!curve.!!With!
the!tipple!raised,!board!will!travel!through!from!the!old!ramp!conveyor.!!Lowering!the!tipple!
frame!allows!product!to!flow!from!the!new!line.!
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The!fully!automated!REL!conveyors!are!designed!and!manufactured!to!be!safe,!robust!and!
controllable,! providing! dependable,! trouble! free! operation! with! minimal!professional!
maintenance.!!All!conveyors!are!provided!with!proper!guarding!to!ensure!safe!operation.!!
Chapter!6!provides!equipment!pictures!and!recommended!spare!parts.!
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This! line!is!controlled!from!two!HMI!screens.!One!is!installed!in!the!Paint!Coater!control!
panel,!CP-2000,!and!the!other!is!in!the!Main!control!panel,!CP-1000.!The!Overview!screen!
shows!the!status!of!each!motor!and!allows!you!to!select!board!size.!Each!Zone!screen!shows!
the!speed!of!each!motor!in!that!zone!and!with!security!login,!allows!you!to!manually!turn!on!
all! the! motors! in! that! zone.! The! Alarm! Summary! screen! shows! a! list! of! alarms.! It! can! be!
accessed!by!pressing!the!“Go!To!Alarm”!button!on!the!Overview!screen.!
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The!Overview!screen!is!for!monitoring!the!system!and!selecting!the!main!control!functions.!
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• Motor!Status:!
o Each!motor!will!be!green!if!it!is!running,!grey!if!it!is!off,!or!red!if!it!is!faulted!
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• Servo!Motor!Status:!
o The!servo!motors!will!be!green!if!they!are!ready!and!grey!if!they!are!off!or!
faulted!
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• Alarm/faulted!motors/servos:!
o In!the!event!that!a!motor!faults,!an!alarm!will!be!triggered!and!it!will!turn!red!
on!the!Overview!screen!
o All! active! alarms! will! scroll! across!the! bottom! of! the! Overview! screen! and!
across!the!top!of!its!respective!Zone!screen.!
o Alarms!can!also!be!viewed!on!the!Alarm!Summary!screen!
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• Zone!STATUS!
o There!is!an!indicator!for!each!zone,!this!will!show!gray!when!the!zone!is!not!
active!and!it!will!show!green!when!the!zone!is!enabled!(or!active)!
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• ESTOP!Status!
o This!indicator!will!show!green!when!an!ESTOP!is!not!tripped!and!it!will!show!
red!when!an!ESTOP!is!tripped!
o ESTOP!NOTES:!
• There!are!(3)!ESTOPs!on!the!system,!one!each!in!CP-1000,!CP-2000,!
and!on!the!Stacker/Accumulator!Area!guarding!inside!of!the!line!
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• System!Restart!
o After!ESTOP:!
• To!restart!the!line!after!an!ESTOP!was!pressed!use!the!start!zone!##!
motors! button! in! all! the! zones! starting! with! zone! 7! and! counting!
down!
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o After!Zone!Fault:!
• To!restart! after!a!Zone!fault! start!the!zones!that!stopped!from!the!
highest!number!to!the!lowest!
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o During!a!startup!sequence:!
• If!a!zone!faults!out!during!a!startup!sequence!fix!the!fault!and!start!
the!faulted!zone!and!the!startup!sequence!will!continue.!
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o Zone!5!or!Zone!6!Lock!out:!
• If!Zone!5!or!6!is!locked!out!each!of!the!servo!motors!will!have!to!be!
reset!using!the!reset!popup!accessed!by!clicking!on!each!servo.!
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• REMOTE/LOCAL!Mode!selection!
o This!button!is!security!protected,!you!have!to!be!logged!in!to!change!it!
o During!normal!run!the!line!will!be!in!REMOTE!mode!
o In! REMOTE! mode! the! line! will! be! started/stopped! from! the! main! plant!
DCS/Control!System!
o In!LOCAL!mode!the!line!can!be!started/stopped!from!the!(2)!local!HMIs!
• A!“START!SYSTEM”!button!will!be!visible!in!Local!mode!
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• PRODUCT!SIZE!selection!
o This!button!is!NOT!security!protected!
o This!button!selects!the!board!size!(4’!x!8’!or!4’!x!10’)!
o Note:!!The!product!size!cannot!be!changed!when!the!stop!fence!is!down.!
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• NO!FLIP/FLIP!selection!
o This!button!is!NOT!security!protected!
o This!changes!the!mode!of!the!system!to!flip!the!boards!or!NOT!flip!the!boards!
o In!FLIP!mode!the!button!will!be!light!gray!and!will!read!“PRESS!FOR!NO!FLIP!
MODE”!
o In!NO!FLIP!mode!the!button!will!be!dark!gray!and!will!read!“PRESS!FOR!FLIP!
MODE”!
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Pressing!the!“Login”!button!on!any!screen!allows!the!user!to!select!Access!Level!and!login!
and!logout.!Entering!an!incorrect!password!will!cause!the!system!to!logout!of!the!current!
Access!Level.!
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Figure 2: Overview Screen
Figure 3: Login Screen

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The!screens!for!Zone!0,!Zone!3,!Zone!4,!Zone!6!and!Zone!7!are!all!very!similar.!They!show!
each! motor! in! its! respective! zone,! and! the! number! below! each! motor! represents! the!
percentage!at!which!it!is!running.!The!“Start/Stop!Zone!XX!Motors”!button!allows!users!with!
access!to!start!an!individual!zone.!!The!box!on!the!top!of!the!screen!is!where!alarms!just!for!
that!respective!zone!will!scroll.!The!status!box!next!to!each!motor!reflects!the!mode!that!each!
motor!is!in,!which!are!described!below:!
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• Grey!à!Set!to!Auto!Mode!à!Off!
• Green!à!Set!to!Auto!Mode!à!On!
• Orange!à!Set!to!Manual!Mode!à!Off!
• Yellow!à!Set!to!Manual!Mode!à!On!
• Red!à!Fault!
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The!Zone!0!screen!also!has!indication!for!the!signal!between!our!control!system!and!the!main!
plant!control!system!upstream!and!downstream!from!this!system.!!The!signals!will!show!
gray!when!they!are!off!and!green!when!they!are!on.!
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Figure 4: Zone Screen

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• 70/40!MODE!–!this!is!the!main!start/stop!signal!for!REMOTE!mode.!!This!is!also!the!
signal!that!will!shift!the!tipples!down!at!the!infeed!and!outfeed!of!the!line!
• DOWNSTREAM! LINE! READY! FOR! PRODUCT! –! This! is! on! when! the! downstream!
system!is!ready!to!accept!product!from!our!line.!!If!this!is!not!on!the!system!will!go!
into!“STACK”!mode!on!the!accumulator!
• DRYER!AT!SET!TEMPERATURE!–!This!is!a!signal!from!the!dryer!that!indicates!that!
the!dryer!is!at!temperature!
• DRYER!CONVEYORS!RUNNING!–!This!is!a!signal!from!the!dryer!that!indicate!the!dryer!
conveyors!are!running!
o NOTE!about!this!signal!–!this!signal!will!turn!on!the!dryer!out!feed!motor!B7!
as!long!as!our!system!is!powered!up!
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• 70/40!MODE!–!this!indicates!that!our!system!is!ready!to!accept!board!from!the!plant.!!
This!signal!will!drop!out!anytime!there!is!a!problem!in!one!of!our!zones!
• ACCUMLATOR!STACKING!–!indicates!that!we!are!accumulating!board,!stacking!it!up!
• ACCUMLATOR!FEEDING!–!indicates!that!the!accumulator!is!being!unloaded,!feeding!
the!downstream!system!
• ACCUMLATOR! FEED! THRU! –! indicates! that! the! accumulator! is! not! stacking! or!
feeding/unloading,!board!is!passing!thru!the!accumulator!
• DRYER!AT!SET!TEMPERATURE!–!This!is!a!signal!from!the!dryer!that!indicates!that!
the!dryer!is!at!temperature!
• DRYER!CONVEYORS!RUNNING!–!This!is!a!signal!from!the!dryer!that!indicate!the!dryer!
conveyors!are!running!
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Figure 5: Zone 3

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All!of!the!above!regarding!Zone!screens!also!applies!to!Zone!1.!However,!the!Zone!1!screen!
also!allows!you!to!turn!on!the!paint!system!and!manually!turn!on/off!the!paint!motors.!
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The!Zone!5!screen!has!the!same!features!as!the!other!screen!with!the!ability!to!reset!faulted!
servos!and!turn!the!blowers!on!and!off.!If!a!servo!remains!grey!instead!of!starting!with!the!
rest!of!the!servos!it!can!be!reset!by!pressing!on!the!servo!and!pressing!the!reset!button!on!
the!popup!screen.!
Figure 6: Zone 7
Figure 7: Zone 1

www.relinc.com! ! iREL!Systems!
14!
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The! Alarm! Summary! screen! shows! all! alarms.! The! text! of! the! alarm! will! initially! be! red.!
Alarms!can!be!acknowledged!by!selecting!them!on!this!screen.!The!text!for!acknowledged!
alarms!will!be!yellow,!and!turn!to!green!once!the!alarm!trigger!has!become!false.!To!delete!
specific!alarms,!select!the!alarm!and!press!the!“Delete!Selected!Acknowledged!Alarm”!button.!
To!clear!all!alarms,!press!the!“Clear”!button.!!
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Figure 8: Zone 5
Figure 9: Alarm Screen

www.relinc.com! ! iREL!Systems!
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Users!with! access! can! manually!operate! each! motor.!The! Manual-Off-Auto! (MOA)! screens!
can!be!viewed!by!pressing!on!the!motor!icon!for!the!desired!motor.!When!a!motor!is!in!Auto!
mode,!you!cannot!change!its!speed.!If!the!motor!is!in!Off!or!Manual!mode,!a!numeric!input!
box!will!appear.!Press!on!the!box!to!change!the!motor!speed.!!
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Figure 10: Zone 0 Motors
Figure 11: Zone 0 Motors

www.relinc.com! ! iREL!Systems!
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During!the!course!of!operation!of!all!REL!custom!conveying!equipment,!some!routine!
maintenance!will!be!required.!!This!includes!such!things!as!belt!inspection,!bearing!
lubrication,!inspection!of!belt!guides!and!edge!guides,!etc.!!Links!to!manufacturers’!
recommendations!are!included!in!the!appendix!section!of!this!manual.!!Proper!
housekeeping/cleanliness!will!ensure!trouble!free!operation.!
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All!belt!idler!sheaves!have!lube!for!life!sealed!ball!bearings.!!The!drive!shafts,!conveyor!
rollers,!and!servo!pivot!shafts!have!pillow!block!style!bearings!with!zerk!fittings!for!
lubrication.!!!
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A!routine!belt!inspection!would!include!a!quick!visual!and!noise!inspection,!once!a!month.!!
A!more!complete!inspection!should!include!such!things!as!ensuring!proper!belt!tension,!
alignment,!drive!component!wear,!etc.!!Inspect!belts!for!wear!or!damage!and!replace!as!
needed.!
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www.relinc.com! ! iREL!Systems!
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This% equipment% does% not% contain% any% mercury% or% mercury% compounds.% % This%
equipment%does%not%contain%any%asbestos%or%materials%containing%asbestos.%%This%
equipment% does% not% have% materials% containing% any% polychlorinated% biphenyl%
(PCB).%%This%equipment%does%not%contain%any%Class%1%Ozone%Depleting%Substances.%
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Machine! owners,! operators,! maintenance! personnel,! and! service! personnel! must!
know!that!safety!practices!are!a!vital!part!of!the!job.!!Whenever!maintenance!or!repair!
is!performed!on!any!part!of!the!Line,!all!equipment!must!be!in!a!zero!energy!state!and!
proper!lockout/tagout!procedures!must!be!performed.!
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When! putting! equipment! in! a! zero! energy! state,! the! operator! may! encounter! the!
following!energy!sources:!
• Electrical!power!
• Pressurized!air!
• Components!that!can!fall!
• Other!potential!hazards!not!listed!here!
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Figure 12: REL's integrated safety features- Proximity Sensors (left); Emergency Stops (middle); Light Curtains (right)!
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Preventive! maintenance! (PM)! is! essential! for! the! proper! operation! of! the! Line.!!
Elements!of!an!effective!PM!program!include!documentation,!verification!of!proper!
operation,!routine!maintenance,!inspection,!spare/replacement!parts,!and!electrical!
maintenance.!
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Do!not!attempt!to!perform!any!maintenance!on!equipment!until!all!safety!instruction!
have!been!reviewed!and!all!power!sources!are!locked!out!as!described!in!Chapter!3!-!
Safety.!
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All!of!the!mounted!bearings!require!grease!lubrication.!
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See! manufactures! recommendations! regarding! changing! oil! in! the! drive! motor!
gearbox.!
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The!wear!strips! on!each!conveyor!section! should!be!inspected!after!every!year!of!
operation.!!Replace!the!wear!strip!if!it!shows!signs!of!excessive!wear.!
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Figure 13: Corner Turn Tipple Conveyor
Figure 14: Corner Turn Tipple Conveyor